kiln operation.ppt
TRANSCRIPT
Training for Pioneer Cement Operation
Kiln Operation
Pioneer Cement22-28 July 2006
Prepared by Hatsachai prahanphapSiam cement (Ta-Luang) Co.,ltd
Training for Pioneer Cement Operation
Content• Quality of Clinker • Kiln Operation Parameter• Cooler Operation• Burner Operation
Training for Pioneer Cement Operation
Clinker quality• Clinker
Component– SiO2 22.8%– Al2O3 5.98%– Fe2O3 3.42%– CaO 63.95%
• Compound in Clinker– 3.CaO.SiO2 , C3S– 2.CaO.SiO2 , C2S– 3.CaO.Al2O3 , C3A– 4.CaO.Al2O3.Fe2O
3 ,C4AF
Training for Pioneer Cement Operation
Clinker Quality• C3S (Give initial strength of concrete)
- 407 76= . CaO . SiO2 - 672 2O3 - 143. Fe2O3
= 42.0% • O2O (Give late strength of concrete
= 8 .6 SiO2 + 5 .0 7 2O3 108+ . Fe2O 3 - 307. COO= 33.8%
• O3O (Give some initial strength and give the plasticity of mortar)
265= . Al2O3 - 169. Fe2O3= 10.06%
• O4OO 304= . Fe2O3 =10.4%
Training for Pioneer Cement Operation
Quality concern Kiln operation
• LSF CaO / (2.8SiO2+1.18Al2O3+0.65Fe2O3)( LSF <90 easy burn , >98 hard burn)Higher LSF ,
- Harder burn clinker - Use higher fuel consumption- Higher C3S
Normal fluctuation = Setpoint +/- 1.5Pioneer cement LSF-Cli = 88% (expect 90%)
Training for Pioneer Cement Operation
Quality concern Kiln operation
• Ms SiO2 / (Al2O3 + Fe2O3)(Ms <2.0 easy burn , >3.0 hard burn)Higher Ms = Higher Silica - Harder burn clinker - Higher Fuel consNormal fluctuation = setpoint +/- 0.1
Training for Pioneer Cement Operation
Quality concern Kiln operation
• Ma Al2O3 / Fe2O3(Ma <1.3 easy burn , >2.5 hard burn)
Fe2O3 is better fluxing agent than Al2O3 Higher Ma = Harder burn clinker
Normal Fluctuation = setpoint +/- 0.1
Training for Pioneer Cement Operation
Quality concern Kiln operation
• FCaO– Remain CaO from incomplete reactivity
of clinkering process – High FCaO = Dusty Clinker– FCaO > 1.5%
Lead to expansion of mortar and concrete
Training for Pioneer Cement Operation
Kiln Operation Parameter
Input
Operation
Output
-Rawmeal Quality ( R90u, R200u, LSF ,Ms ,Ma)-Coal Quality ( R90u , LHV)
-Kiln feed , Filling Degree-Fuel Feed rate , Fuel Ratio-Burning Zone Temp -Kiln Torque (Amp of Motor)-Calciner Temperature-O2 , CO at K-line , C-line-Degree of Calcinations-Clinker Cooler Operation-FCaO -LSF -Ms -Ma -Liter weight
Training for Pioneer Cement Operation
Kiln Input• Kiln feed
– Fineness of Kiln feed : Residue on 200u sieve should less than 1.0%
– Quality of kiln feed (LSF , Ms ,Ma) are according to clinker quality
Training for Pioneer Cement Operation
Kiln Input• Fuel
– Fineness of fuel 0.5 -0.8* VM(dry ash free)
– Coal Analysis in As fired basisVM 39.46% , Ash 13.9% ,Moist 1.0%VM(dry ash free)
= 39.46*100/(100-13.9-1)= 46.3
– Fineness of Coal 0.5 x 46.3 = 23%
Training for Pioneer Cement Operation
Kiln Operation• Filling Degree
F = 3.2 x P D3 x H x NF = 3.2 x 4000 4.23x3.5x2.8F = 17.6%
Training for Pioneer Cement Operation
Kiln Operation• Kiln in hot condition
– Kiln amp increase– Burning Zone temp increase– Clinker has a good quality
•FCaO Low•Liter weight high
– At this condition O/P can increase feed 5-10 t/h in each 15-30min
Training for Pioneer Cement Operation
Kiln Operation• Kiln in cold condition
– Kiln amp decrease– Burning Zone temp decrease– Clinker has a poor quality
•FCaO higher•Liter weight lower
– At this condition O/P have to carefully observe the kiln
– Decrease Kiln speed – Decrease feed if necessary
Training for Pioneer Cement Operation
Kiln Operation• Calciner Control
– Control the temperature of Calciner constant (as possible) in range 860-880 C
– Check Degree of CalcinationsDOC = ( LOI[KF] – LOI[C4] )x100
(100 – LOI[C4])x(LOI[KF] /100)-LOI[KF] : Loss on ignition of Kiln feed-LOI[C4] : Loss on ignition of C4 Material
- DOC should control in range 90-95%
Training for Pioneer Cement Operation
Kiln Operation• Degree Of Calcination
Training for Pioneer Cement Operation
Kiln Operation• Free Lime, FCaO
– Control Range 0.5-1.5%– FCaO < 0.5
•Hard burn clinker•Lead to snowman at Cooler•Use higher heat consumption•Harmful to brick life
Training for Pioneer Cement Operation
Kiln Operation• Free Lime, FCaO
– FCaO > 1.5 •Low quality of clinker•Dusty clinker
Training for Pioneer Cement Operation
Kiln Operation• O2 at Kiln and Calciner
– Control >2.0% •Keep complete combustion in kiln and
Calciner•C + O2 -> 2CO : E = 2500 kcal/kg-C•C + O2 -> CO2 : E = 8060 kcal/kg-C•Heat loss 69% with CO condition
Training for Pioneer Cement Operation
Clinker Bed• Higher clinker bed can increase heat
recuperation from clinker cooler• Clinker Bed
1.15xT/Dx1000 (1.2x24x60)x (WxLxst) W = Grate width 3.6m L = Stroke length 150mm St = Stroke/min or rpm
Training for Pioneer Cement Operation
Clinker Cooler Operation• Combustion Air
– 0.85 Nm3/kg.cli– Use from Fan K11 – K30
• Heat Recuperation– Secondary Air temp > higher than 960
C– Tertiary Air temp > higher than 960 C
Training for Pioneer Cement Operation
Existing Clinker Cooler Operation
Too much air at K11-K23Control this value in range 0.85 Nm3/kg.cli
Control this value in range 2.1 Nm3/kg.cli
Training for Pioneer Cement Operation
Clinker Cooler Operation
Training for Pioneer Cement Operation
Clinker Bed• At 2,800 t/d ,G1 = 10.5 ,G2 = 11.5 stk/min
– Clinker bed G11.15 x 2800 x 1000 = 330 mm(1.2 x 24 x 60) x (3.6 x 0.15 x 10.5 )
– Clinker bed G21.15 x 2800 x 1000 = 300 mm(1.2 x 24 x 60) x (3.6 x 0.15 x 11.5 )
• Recommend Clinker bed > 500mm
Training for Pioneer Cement Operation
Burner Operation• Flame Momentum
– Primary Air (% of A) x Velocity (%.m/s)
• Stoichiometric air require– Ao = 1.01x(LHV+550)/1000 Nm3/kg.fuel– m = excess air 10-20%– A = (1+m)xAo
Training for Pioneer Cement Operation
Burner Operation• Velocity
– V = 4.4 x sqrt(10.2 x P) P = Fan Pressure – 20
• Flame Momentum– 1500 – 1700 %xm/s
Training for Pioneer Cement Operation
Burner Operation